Balloon with a pocket and method of making

ABSTRACT

A non-latex balloon has at least two outer balloon layers of a polymer such as nylon, with an inner layer of heat-sealable material. A self-sealing valve is heat-sealed to the inner surface of one of the outer layers. An inner balloon layer is placed adjacent the outer balloon layers and heat-sealed to one of them to form an enclosed pocket. Two inner balloon layers may be used to form two pockets. The seal of the pockets may be releasable by the user to put a sundry item into the pocket or the sundry item may be manufactured into the pocket. A method of manufacture of a balloon product includes the steps of: placing a valve between two outer sheets of heat-sealable material; placing an inner sheet of material between the two outer sheets; and heat-sealing the valve to the outer sheets and heat-sealing the inner sheet to an outer sheet to form a sealed balloon with a pocket between the inner sheet and the outer sheet. Two pockets may be produced by using a second inner sheet.

BACKGROUND OF THE INVENTION

The present invention relates generally to non-latex balloons and more particularly to a non-latex balloon having a resealable pocket for display and holding of various items.

Non-latex balloons have been popular for many years. Non-latex balloons, often referred to as metallized balloons, are characterized as balloons that are comprised of materials that have no elastic properties. Such materials include plastic, foil, mylar, and nylon. A variety of non-latex balloons have been made available to the public, including brightly colored, transparent, and even multi-layered balloons. Further, balloons which centrally house various materials have been produced. See, for example, U.S. Pat. Nos. 5,338,243, 4,837,955, 5,254,026 and 5,108,339 the teachings thereof which are herein incorporated by reference. Further, a self-sealing valve has been introduced, which allows the balloon to be easily and quickly inflated and further eliminates the need for tying or heat-sealing of the balloon stem. See U.S. Pat. No. 4,917,646 and the teachings thereof which are incorporated herein by reference.

The aforementioned balloons include various embodiments, some which feature display and containment of centrally-housed items. These balloons, however, are constructed solely for purposes of displaying items which are affixed and contained within the balloon and thereby further limit the outer layer of the balloon, requiring transparency. In addition, balloons which feature display of a centrally-housed item require manufacture of a singular constructable component to structurally support the centrally-housed item, whether by permanent seal of a centrally-housed item, manufacture of a singular housing fixture, which is centrally housed, or a support umbilical which holds the item in a fixed position. Further, the items for display are limited, due to manufacturing and housing constraints. For example, inserting items for display and containment during the manufacturing process can provide for a more economical distribution of the product. Further, providing a versatile yet predictable containment region will permit insertion of as few as one (for example, a piece of candy) or multiple items (for example, confetti) during the manufacturing process. Further, providing a versatile means of both inserting and removing items from the containment region will allow for a variety of uses for the balloon product. Lastly, providing a streamlined manufacturing process using similar materials, as well as simultaneous heat-sealing and adhesion capabilities, makes the process more efficient and economical.

There is a need for a balloon which overcomes the display and containment limitations herein discussed, and which further provides an efficient and economical method of manufacture regarding the same.

SUMMARY OF THE INVENTION

A non-latex balloon has at least two outer balloon layers of a polymer such as nylon, with an inner layer of heat-sealable material. A self-sealing valve is heat-sealed to the inner surface of one of the outer layers. An inner balloon layer is placed adjacent the outer balloon layers and heat-sealed to one of them to form an enclosed pocket. Two inner balloon layers may be used to form two pockets. The seal of the pockets may be releasable by the user to put a sundry item into the pocket or the sundry item may be manufactured into the pocket. A method of manufacture of a balloon product includes the steps of: placing a valve between two outer sheets of heat-sealable material; placing an inner sheet of material between the two outer sheets; and heat-sealing the valve to the outer sheets and heat-sealing the inner sheet to an outer sheet to form a sealed balloon with a pocket between the inner sheet and the outer sheet. Two pockets may be produced by using a second inner sheet.

A principal object and advantage of the balloon is to provide a display and/or containment pocket of simple construction.

Another principal object and advantage of the balloon is to provide a display and/or containment pocket of inexpensive construction.

Another principal object and advantage of the balloon is to provide a display and/or containment pocket that may be removed or modified to insert items.

Another principal object and advantage of the balloon is to provide a display and/or containment pocket that can hold a variety of items.

Another principal object and advantage of the balloon is to provide a display and/or containment pocket that may be decorative and functional.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevational view of a balloon product.

FIG. 2 is a side cross-sectional view of a balloon product.

FIG. 3 is a front elevational view of a second embodiment of a balloon product.

FIG. 4 is a cross-sectional view of a balloon product taken at approximately the lines 4 of FIG. 3.

FIG. 5 is a perspective view of a third embodiment of a balloon product.

FIG. 6 is a side elevational view of a balloon product.

FIG. 7 is a detailed view of a balloon product of the circled area of FIG. 5

FIGS. 8 and 9 are schematic views of a method of manufacture of a balloon product.

FIG. 10 is a schematic of the construction of the balloon layers.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A first embodiment of the present invention is generally shown in the FIGS. as reference numeral 10.

The first embodiment (FIGS. 1 and 2) is a non-latex balloon 10, comprising at least two outer balloon layers 12 a, 12 b, each outer balloon layer having an edge 14, an outer surface 16, and an inner surface 18, the inner surfaces 18 having a heat sealable material 20.

The non-latex balloon 10 further comprises a self-sealing valve 22, the valve 22 being heat-sealed to the inner surface 18 of one of the edges 14 of one of the outer layers 12 a, 12 b.

The non-latex balloon 10 further comprises an inner balloon layer 24 having an outer surface 26, an inner surface 28, and an edge 30, the inner layer 24 being placed adjacent the outer layers 12 a, 12 b. The inner surface 18 of one of the outer layers 12 a, 12 b is heat-sealed to the outer surface 26 of the inner layer 24 at the edge 30, thereby forming an enclosed pocket 32.

Preferably, the heat-sealable material 20 comprises linear low-density polyethylene 20 a. In the preferred construction, the outer surface 26 of the inner layer 24 and the inner surface 18 of the outer layers 12 a, 12 b comprise this heat-sealable material.

The balloon 10 may optionally further comprise a metallic layer 21 on the outer surface 26 of the inner layer 24, thereby making the pocket 32 opaque. Preferably, the metallic layer 21 comprises vacuum-deposited aluminum.

A sundry item 40 may be enclosed in the pocket 32, either during manufacture or later. In order to permit such an item to be inserted in the pocket 32 after manufacture, the outer layer 12 a or 12 b is releasable from the inner layer 24. Alternatively, as shown in FIG. 3, the pocket 32 may have an access opening 25.

A second embodiment of the present invention is generally shown in the FIGS. as reference numeral 110.

The second embodiment is a non-latex balloon 110 comprising two outer balloon layers 12 a, 12 b, each outer balloon layer having an edge 14, an outer surface 16, and an inner surface 18, the inner surfaces 18 having a heat sealable material 20.

The non-latex balloon 110 further comprises a self-sealing valve 22, the valve 22 being heat-sealed to the inner surface 18 of one of the edge 14 of one of the outer layers 12 a, 12 b.

The non-latex balloon 110 further comprises two inner balloon layers 24 a, 24 b, each having an outer surface 26, an inner surface 28, and an edge 30, the inner layers 24 a, 24 b being placed adjacent to the outer layers 12 a, 12 b. The inner surfaces 18 of each of the outer layers 12 a, 12 b are heat-sealed to the outer surfaces 26 of the inner layers 24 a, 24 b at the edges 30, thereby forming enclosed pockets 32 a, 32 b. To promote this, the outer surfaces 26 of the inner layers may also have a heat-sealable material 20. The inner surfaces 28 of each of the inner layers 24 a, 24 b comprise a material resistant to heat-sealing, such as nylon.

A third embodiment 210 of the present invention is shown in FIG. 5. The balloon 210 is similar to the previous embodiments with the addition of a second valve 222 to inflate one of the pockets 32 a, 32 b.

The preferred structure of the outer layers 12 a, 12 b and the inner layers 24 a, 24 b is shown in FIG. 10. As can be seen, each of the layers is constructed of a plastic polymer 15 such as polyolefin, nylon, polyester, polyethylene, etc. The layers should be substantially clear to allow a user to see into the balloon. The material may also include vacuum-deposited aluminum 21 as discussed above. Where it is desirable for the layers to bond together (as in the facing surfaces of the two outer layers) a heat sealable material 20 such as linear low-density polyethylene (LLDP) may be applied to the nylon or other material over a layer of primer 17. Otherwise, the material 15 of the layers (such as nylon) is not sealable by applied heat.

A method of manufacturing a balloon product is shown in FIGS. 8 and 9 comprises the steps of: (a) placing a valve 22 between two outer sheets 12 a, 12 b of heat-sealable material; (b) placing an inner sheet 24 a between the two outer sheets 12 a, 12 b; and (c) heat-sealing the valve 22 to at least one outer sheet and heat-sealing the inner sheet to one of the outer sheets, thereby forming a sealed balloon with a pocket 32 between the inner sheet 24 and an outer sheet 12 a or 12 b. To make a balloon with two pockets, the method comprises the additional steps of: (d) placing a second inner sheet 24 b of material between the outer sheets 12 a, 12 b; (e) temporarily adhering the two inner sheets 24 a, 24 b to one another to keep them in alignment; and (f) heat sealing the second inner sheet 24 b to the other outer sheet 12 a or 12 b. In order to prevent the two inner sheets 24 a, 24 b from heat-sealing to each other, the inner surface 28 of the inner sheets comprises a layer of non-heat sealable material 20.

The method is schematically illustrated in FIGS. 8 and 9, in which material for the outer sheets 12 a, 12 b is unwound from rolls 300 as the two inner sheets 24 a, 24 b are placed adjacent to one of the outer sheets, followed by the valve 22. A spot 302 of adhesive is placed between the two inner sheets to keep them in alignment. Tack adhesive 303 may also be applied between the outer layers and inner layers to keep them in alignment. The complex of outer sheets, inner sheets, and valve is then carried past a first pair of heat seal dies 304 so that the first pair 304 of heat seal dies line up with the valve 22, thus heat-sealing the valve 22 to the two outer sheets 12 a, 12 b. Next, the complex is carried past a second pair 306 of heat seal dies, a third pair 308 of heat seal dies, and a fourth pair 310 of heat seal dies which preferably simultaneously heat-seal the inner sheets to the outer sheets and the outer sheets to each other. The complex is then cut at cut lines 312 to produce a balloon for shipment. At the time of inflation, the spot of adhesive 302 is broken as the inner layers 24 a, 24 b separate from each other. 

1. A non-latex balloon comprising: (a) at least two outer balloon layers, each outer balloon layer having an edge, an outer surface, and an inner surface, the inner surfaces having a heat-sealable material; (b) a self-sealing valve, heat-sealed to the inner surface of the edge of one outer balloon layer; (c) an inner balloon layer having an outer surface, an inner surface, and an edge, placed adjacent the outer balloon layers; and (d) wherein the inner surface of one outer balloon layer is heat-sealed to the outer surface of the inner balloon layer at the edges of the inner balloon layer, thereby forming an enclosed pocket therebetween.
 2. The balloon of claim 1, wherein the heat-sealable material further comprises linear low-density polyethylene.
 3. The balloon of claim 1, further comprising a metallic layer on the outer surface of the inner balloon layer.
 4. The balloon of claim 3, wherein the metallic layer comprises vacuum-deposited aluminum.
 5. The balloon of claim 1, further comprising a sundry item enclosed in the pocket.
 6. The balloon of claim 5, wherein the outer balloon layer is releasable from the inner balloon layer at the edges of the pocket, thereby permitting access to the sundry item.
 7. The balloon of claim 1, further comprising an access opening in the outer balloon layer over the pocket, thereby permitting sundry items to be inserted in the pocket.
 8. A non-latex balloon comprising: (a) two outer balloon layers, each outer balloon layer having an edge, an outer surface, and an inner surface, the inner surfaces having a heat-sealable material; (b) a self-sealing valve, heat-sealed to the inner surface of the edge of one outer balloon layer; (c) two inner balloon layers, each having an outer surface, an inner surface, and an edge, the inner surfaces comprising a material resistant to heat-sealing, placed adjacent the outer balloon layers; and (d) wherein the inner surface of each outer balloon layer is heat-sealed to the outer surface of the corresponding inner balloon layer at the edges of the inner balloon layer, thereby forming an enclosed pocket therebetween.
 9. The balloon of claim 8, wherein the heat-sealable material further comprises linear low-density polyethylene.
 10. The balloon of claim 8, further comprising a metallic layer on the outer surface of the inner balloon layer.
 11. The balloon of claim 10, wherein the metallic layer comprises vacuum-deposited aluminum.
 12. The balloon of claim 8, further comprising a sundry item enclosed in the pocket.
 13. The balloon of claim 12, wherein the outer balloon layer is releasable from the inner balloon layer at the edges of the pocket, thereby permitting access to the sundry item.
 14. The balloon of claim 8, further comprising an access opening in the outer balloon layer over the pocket, thereby permitting sundry items to be inserted in the pocket.
 15. A non-latex balloon comprising: (a) at least two outer balloon layers, each outer balloon layer having an edge, an outer surface, and an inner surface, the inner surfaces having a heat-sealable material; (b) a self-sealing valve, heat-sealed to the inner surface of the edge of one outer balloon layer; (c) an inner balloon layer having an outer surface, an inner surface, and an edge, placed adjacent the outer balloon layers; (d) wherein the inner surface of one outer balloon layer is heat-sealed to the outer surface of the inner balloon layer at the edges of the inner balloon layer, thereby forming an enclosed pocket therebetween; and (e) a valve communicating with the pocket for inflating the pocket.
 16. The balloon of claim 15, further comprising an additional inner balloon layer opposing the first inner balloon layer, the opposing surfaces of the inner balloon layers comprising a material resistant to heat sealing.
 17. A method of manufacturing a balloon product, comprising the steps of: (a) placing a valve between two outer sheets of heat-sealable material; (b) placing an inner sheet of material between the two outer sheets, and (c) heat-sealing the valve to the outer sheets and the inner sheet to an outer sheet, thereby forming a sealed balloon with a pocket between the inner sheet and the outer sheet.
 18. The method of claim 18, further comprising the steps of: (d) placing a second inner sheet of material between the two outer sheets; (e) temporarily adhering the two inner sheets to one another; and (f) heat sealing the second inner sheet to the other outer sheet.
 19. The method of claim 18, wherein the inner sheets each comprise an inner surface of non-heat sealable material, thereby preventing the inner sheets from sealing to one another.
 20. The method of claim 19, further comprising the step of cutting through the outer and inner layers to produce a finished balloon. 